Installation Manual 1000K Page 1 of 10 May 2015 Tuf-Lite III ® Fans I000K Series Auto-Variable ® Hub INSTALLATION MANUAL Hudson Auto-Variable ® Hubs and Tuf-Lite III ® Fan Blades Hudson Auto-Variable ® (AV) hubs feature Timken tapered roller bearings and synthetic lubricants. All com- ponents are suitable for high and low temperature operation and are interchangeable (except hub bodies) in 4, 5, or 6 blade configurations. Hudson AV hubs are durable and designed for low maintenance and energy sav- ing operation. Hudson Tuf-Lite III ® fan blades are of single piece fiberglass reinforced plastic (FRP) construction optimized for performance, reliability, noise, and cost effectiveness. Tuf-Lite III ® fan blades are constructed of light weight, corrosion resistant, fiberglass reinforced vinyl-ester resin, with materials, thickness, and processes determined from finite element analysis modeling. Tuf-Edge ® leading edge erosion and UV protection is a standard with this blade. The individually balanced blades can be replaced independently—matched sets are not required.
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Installation Manual 1000K Page 1 of 10 May 2015
Tuf-Lite III® Fans
I000K Series Auto-Variable® Hub
INSTALLATION MANUAL
Hudson Auto-Variable® Hubs and Tuf-Lite III
® Fan Blades
Hudson Auto-Variable® (AV) hubs feature Timken tapered roller bearings and synthetic lubricants. All com-
ponents are suitable for high and low temperature operation and are interchangeable (except hub bodies) in 4,
5, or 6 blade configurations. Hudson AV hubs are durable and designed for low maintenance and energy sav-
ing operation.
Hudson Tuf-Lite III® fan blades are of single piece fiberglass reinforced plastic (FRP) construction optimized
for performance, reliability, noise, and cost effectiveness. Tuf-Lite III® fan blades are constructed of light
weight, corrosion resistant, fiberglass reinforced vinyl-ester resin, with materials, thickness, and processes
determined from finite element analysis modeling. Tuf-Edge® leading edge erosion and UV protection is a
standard with this blade.
The individually balanced blades can be replaced independently—matched sets are not required.
Installation Manual 1000K Page 2 of 10 May 2015
RECOMMENDED TOOLS
Long T-Handle Allen Wrench Set (3/16" to 3/8")
Medium Size Flat Head Screw Driver
Brass Ball Peen Hammer
Flat Bastard File
240 Grit Sand Paper
Anti-Seize Lubricant
WD-40
12" Crescent Wrench
Shop Towels
Exact-A-Pitch® Digital Protractor (P/N 62375)
25 ft. Measuring Tape
Pencil or Marker
Open/Box End Wrench Set (1/2" – 1-1/2")
Socket Set for 1/2" Drive (1/2" – 1-1/2")
Torque Wrench(s) Rated for 0-200 ft-lb
Dial Indicator
INSTALLATION PROCEDURES
Clean all mating surfaces between fan shaft and coupling. All
grease and lubricant should be removed, leaving the mating
surfaces dry.
ASSEMBLY WITH BUSHING
Slide bushing and key onto straight fan shaft. Depending on
shaft size, an R-2 bushing or a Q-2 bushing will be supplied.
Tighten set screw in R-2 bushing flange to lock it on shaft. Q-2
bushings have no set screw. Set coupling squarely on bushing
and install the three (3) 3/8" cap screws. Using torque wrench
with 9/16" socket, tighten bolts evenly to recommended stand-
ard of 29 ft-lb (dry) (See Figure 1).
Figure 1
ASSEMBLY WITH TAPERED SHAFT
Align keyways and install coupling evenly on tapered shaft.
Install key in keyways, then install retainer plate. Install 3/4"
cap screw and lock washer through coupling into fan shaft.
Tighten with 1-1/4" socket torque wrench to 125 ft-lb
(lubricated), 130 ft-lb (dry) torque (See Figure 2).
Figure 2
INSTALLATION OF BOTH TAPERED AND
STRAIGHT SHAFTS
Clean mating surfaces of hub and coupling or flanged shaft, if
used, and apply a light coating of anti-seize and lubricating
compound.
Rigidly attach dial indicator and measure the run-out of top
face of coupling (See Figure 3). Rotate coupling and check for
alignment. Adjust coupling until run-out is less than 0.003".
Installation Manual 1000K Page 3 of 10 May 2015
MINIMUM VIBRATION
THE FOLLOWING FOUR STEPS ARE
EXTREMELY CRITICAL
Figure 3
Install hub onto coupling and fasten in place with the four (4)
3/4" cap screws and lock washers used on the hub-shipping
pallet (See Figure 4). Make sure coupling is pulled down even-
ly. Tighten cap screws to recommended standard of 125 ft-lb
(lubricated) or 130 ft-lb torque.
Figure 4
Rigidly attach dial indicator to the air line support or other sta-
tionary object. Measure run-out of the rotary joint (See Figure 5).
Rotate hub 360° to locate point of minimum reading on the dial;
set indicator to read zero at this point.
Rotate coupling 360° while watching indicator at rotary joint for
misalignment reading. Total indicated run-out should be 0.005".
If run-out is over 0.005", mark low point on face of coupling.
Install shims under hub at low point (See Figure 6).
Figure 6
Figure 5
Installation Manual 1000K Page 4 of 10 May 2015
INSTALL TUF-LITE III® BLADES
Remove blade clamp bolts, nuts, lock washers, and blade
clamp halves from hub. Assemble blade clamp halves over
groove in blade neck, and install into hub with thick leading
edge to left and thin trailing edge to right as you stand at end
of blade. In-stall clamp bolts through hub plates and blade
clamp, putting bolt heads on top side, lock washers and nuts
on bottom (See Figure 7). Tighten lightly.
Figure 7
SET PITCH AND TRACK
Use Hudson EXACT-A-PITCH® digital protractor (See Figure
8) or a bubble protractor to set blade pitch. Mount protractor
on a flat bar as a base and place it approximately 1" from tip of
blade. Note pitch on protractor. Rotate fan 360°, noting high
and low pitch readings. Locate place where pitch reading is a
mid-point between high and low pitch readings, and set pitch
at that point.
Figure 8
Rotate blade in socket until digital protractor shows specified
pitch angle to within ±0.2°. Fan pitch angle is shown on fan
specification sheet for design duty. For reverse acting hubs
(fails to minimum air flow on loss of instrument air pressure),
pitch angle should be set with 15 psi instrument signal and 55
psi supply air pressure applied (See "INSTALLING AIR
LINES").
After desired pitch angle is set, raise and lower end of fan blade
and find midpoint of blade travel. Hold blade at the mid-point.
Pull blade back so that it sits against blade clamp. Push blade to
the right to remove all slack.
Use torque wrench to tighten clamp bolts to recommended
standard of 65 ft-lb (lubricated) or 80 ft-lb (dry). Re-check
pitch setting. Blade must be set within ±0.2° of desired pitch
angle. Tighten clamp bolts evenly. DO NOT OVER-TORQUE
CLAMP BOLTS
When bolts are tightened, hold a pencil against top end of blade
and mark the level onto a fixed object, such as a pole or the fan
ring.
Install remaining blades at same place as first blade, following
procedures above. After tightening bolts, mark top end of each
blade in same place first blade was marked. If marks differ by
1/2" or more, adjust blade.
CHECK TRACK
After fan is installed in fan ring, outline top end of each blade
onto fan ring with a marker. The difference between levels of
highest and lowest outlines should not be more than 1/2" (See
Figure 9).
Figure 9
Installation Manual 1000K Page 5 of 10 May 2015
Correct blade track by loosening clamp bolts and adjusting
blade to match track of other blades. Re-tighten bolts and re-
check track and pitch angle setting. Re-tighten blade clamp
bolts to recommended standard of 55 ft-lb (lubricated) or 60 ft-
lb (dry) torque.
INSTALL SEAL DISC
Making sure hole in seal disc is over oil filler assembly, fasten
seal disc to top of hub with six (6) 3/8" cap screws. Put flat
washer against seal disc and lock washer between flat washer
and cap screw. Tighten to recommended standard of 15 ft-lb
(lubricated) or 20 ft-lb (dry). Make sure seal disc is not inverted
and not touching blades (See Figure 10).
Figure 10
NOTE: The purpose of the seal disc is to prevent hot air from
recirculating back down through the hub, increasing efficiency.
CHECKING TIP CLEARANCE
Rotate fan in position inside fan ring to check tip clearance (See
Figure 11). Tip clearance recommendations for specific fan
diameters are noted in table.
Figure 11
Fan Size (ft) Minimum Maximum
5 through 9 1/4" 1/2"
10 through 11 1/4" 5/8"
12 through 14 1/4" 3/4"
Adjust fan ring for proper clearance at all points around its
circumference. To increase clearance, add spacers at fan ring
joints. Use a chisel to maintain correct distance until bolts on
ring are re-tightened (See Figure 12).
Figure 12
If a small adjustment is needed, tighten or loosen nut on fan
strut in area of incorrect clearance (See Figure 13). Make sure
to re-tighten inside jam nut.
Figure 13
Installation Manual 1000K Page 6 of 10 May 2015
INSTALLING AIR LINES
Remove protective shipping cover and install air line(s).
All 1000 series hubs are shipped completely pre-adjusted for
specified spring pre-load and pitch travel.
ROTARY JOINT
Hook up instrument line to connection on rotary joint (See
Figure 14).
Figure 14
Rotary joint assembly used to deliver controlled pressure to
hub has mechanical seal with ball bearings to assure align-
ment. It is very important that the air line is installed with
some slack. IMPORTANT: Do not pull air line to rotary air
joint tight when installing hub. Instrument air pressure
should be 3-15 psi.
VALVE POSITIONER
Connect instrument line to connection marked INSTRU.
Connect supply line to connection marked SUPPLY (See
Figure 15). Instrument line hookup is all that is necessary
before operating. Instrument air pressure should be 3-15 psi.
Valve positioners are adjusted for 3 psi instrument starting
point. Supply air pressure should be set to level according to
table below.
Figure 15
BIAS RELAY
Connect both supply and instrument lines. Check instructions
included with bias relay. If problems are encountered, contact
Hudson fan engineer. Instrument air pressure should be 3-15
psi. Bias relays are adjusted for 3 psi instrument starting point.
Supply air pressure should be set to level according to table
below.
SUPPLY PRESSURE FOR VALVE POSITIONER OR BIAS RELAY
Hub Type Fan Diameter (ft) Blade Type Hub Spring
Supply Pressure (psi)
To Vary Pitch To Check Blade Pitch
Travel at Rest
Standard Acting Hub
8 K Yellow 35 45
9-14 K White 45 55
Reverse Acting Hub
All Sizes All White 45 55
Installation Manual 1000K Page 7 of 10 May 2015
OPERATING INSTRUCTIONS
Start fan and check rotation. Viewed from top (discharge), fan
blades should rotate clockwise.
Hudson recommends to re-verify the blade clamp torque after
the initial 10-15 minutes of cold operation (i.e., the fan doesn’t
need to be exposed to the working temperature of the process).
This will ensure that the blades are settled within the clamps
after the centrifugal forces have acted.
Check motor power consumption to make sure fan is pulling
desired load. CAUTION: If positive pitch is set in summer to
use all available motor amps (nameplate rating), motor could
be overloaded in winter. Design pitch angles usually do not
use all available horsepower; therefore, motors will not be
overloaded at lowest winter temperatures if preset pitch re-
mains unaltered.
For the fans that have remained idle (such as a shut-down or
turn-around), it is highly recommended to re-verify the torque
on the blade clamps before putting it back into operation.
HUB MAINTENANCE
Hub is designed for oil lubrication and is filled with Summit
Syngear 7150 or Shell Omala RL 150 synthetic oil for mini-
mum oxidation and very low evaporation over wide tempera-
ture ranges. For minimum maintenance, Hudson strongly rec-
ommends using only synthetic oil. Under normal conditions oil
level should be checked on a yearly basis.
The rotary joint requires yearly re-lubricating. Fill bearings
with Dow Corning 44 synthetic grease through zerk fitting.
Installation Manual 1000K Page 8 of 10 May 2015
PARTS LIST Tuf-Lite IlI
® Fans - Auto-Variable
® Hubs
1000K Series
ITEM NO.
P/N DESCRIPTION QTY.
BLDS PER HUB
4 5 6
1 Specify
Bore Q2 Bushing (up to 2 5/8 bore) R2 Bushing (2 11/16 to 3/5 bore)
1 1 1
2 65450 65455
Coupling for Q2 Bushing Coupling for R2 Bushing (Specify Bushing)
OPTIONAL EXTRA VALVE POSI-TIONER ASSEMBLY INCLUDES:
39 62215 Air Hose 1 1 1
67 64535 Male Connector 1 1 1
68 64510 Model 73N12F Positioner
(Low Temp/High Temp Diaphragms and O-rings)
1 1 1
69 M2040 Range Spring Holder Sub Assembly 1 1 1
70 64251 64252 64253 64255
Range Spring (as required) 15 Deg. Travel B-W-B 20 Deg. Travel P-W-P 25 Deg. Travel Y-W-Y 30 Deg. Travel R-W-R
1 1 1
71 64540 Male Elbow, 5/16 Tube 1 1 1
72 65515 Range Spring Guide 1 1 1
73 73307 Retainer Ring 1 1 1
54406 Supply Pressure Regulator
0-100 psi, 1/4 NPT (Not Shown) 1 1 1
74 65525 Base Plate 1 1 1
75 64580 Torque Sleeve 1 1 1
76 64565 Spring Pin (1/8 x 1 1/8) 1 1 1
77 65500 Feedback Rod (5 7/8) 1 1 1
78 73213 Silicone O-Ring Seal #2-227 (Furnished when Rotary Joint Spacer is required)
1 1 1
79 65535 Rotary Joint Spacer 4 Blades: Required when Yellow Hub Spring is used. (1104W, 1204W) 6 Blades: Required when Yellow Hub Spring is used. (1106W, 1206W)
1 1 1
80 72315 Cap Screw, 1/4 NC x 1 1/4 (When Rotary Joint Spacer is required)
6 6 6
81 64525 Bearing Seat 1 1 1
82 81112
Seal Disc 42” Dia for 11’ – 14’ AV Fans
1 1 1
83 70325 Eye Bolt, 3/8-16 x 1 1/4, A489 3 3 3
84 72050 Nut, Hex, 3/8-16, SS 3 3 3
85 64529 Gasket, 5/8 Tube Size 6 6 6
Note:
1. Items 83 & 84 for shop handling only, remove after paint.
Installation Manual 1000K Page 9 of 10 May 2015
HUDSON PRODUCTS CORPORATION Auto-Variable
® Hub
Series I000K
Installation Manual 1000K Page 10 of 10 May 2015
Hudson, Auto-Variable, Combin-Aire, Exact-A-Pitch, Fin-Fan, Heatflo, Hy-Fin, Split-Flo, Solo Aire, Stac-Flo, Steamflo, Thermflo, Tuf-Edge, Tuf-Lite, Tuf-Lite II, and Tuf-Lite III are registered trademarks of Hudson Products